Profile of the Aerospace Industry - CLU-IN

131 Pages·1998·0.7 MB·English

Aerospace Industry Sector Notebook Project
EPA/310-R-98-001.
EPA Office of Compliance Sector Notebook Project
Profile of the Aerospace Industry
November 1998
Office of Compliance
Office of Enforcement and Compliance Assurance
U.S. Environmental Protection Agency
401 M St., SW (MC 2221-A)
Washington, DC 20460
Aerospace Industry Sector Notebook Project
This report is one in a series of volumes published by the U.S. Environmental Protection Agency
(EPA) to provide information of general interest regarding environmental issues associated with
specific industrial sectors. The documents were developed under contract by Abt Associates
(Cambridge, MA), Science Applications International Corporation (McLean, VA), and Booz-Allen
& Hamilton, Inc. (McLean, VA). This publication may be purchased from the Superintendent of
Documents, U.S. Government Printing Office. [A listing of available Sector Notebooks and
document numbers is included on the following page.]
All telephone orders should be directed to:
Superintendent of Documents
U.S. Government Printing Office
Washington, DC 20402
[phone]
FAX [phone]
8:00 a.m. to 4:30 p.m., EST, M-F
Using the form provided at the end of this document, all mail orders should be directed to:
U.S. Government Printing Office
P.O. Box 371954
Pittsburgh, PA 15250-7954
Complimentary volumes are available to certain groups or subscribers, such as public and
academic libraries, Federal, State, and local governments, and the media from EPA’s National
Center for Environmental Publications and Information at [phone]. For further
information, and for answers to questions pertaining to these documents, please refer to the
contact names and numbers provided within this volume.
Electronic versions of all Sector Notebooks are available via Internet on the Enviro$en$e World
Wide Web at http://www.epa.gov/oeca/sector/index.html. Enviro$ense is a free, public,
environmental exchange system operated by EPA's Office of Enforcement and Compliance
Assurance and Office of Research and Development. The Network allows regulators, the
regulated community, technical experts, and the general public to share information regarding:
pollution prevention and innovative technologies; environmental enforcement and compliance
assistance; laws, executive orders, regulations, and policies; points of contact for services and
equipment; and other related topics. The Network welcomes receipt of environmental messages,
information, and data from any public or private person or organization. Direct technical
questions to the “Feedback” button on the bottom of the web page.
Cover photograph courtesy of The Boeing Company.
Sector Notebook Project November 1998
Aerospace Industry Sector Notebook Project
Sector Notebook Project November 1998
Aerospace Industry Sector Notebook Project
Sector Notebook Contacts
The Sector Notebooks were developed by the EPA’s Office of Compliance. Questions relating to
the Sector Notebook Project can be directed to:
Seth Heminway, Coordinator, Sector Notebook Project
US EPA Office of Compliance
401 M St., SW (2223-A)
Washington, DC 20460
[phone]
Questions and comments regarding the individual documents can be directed to the appropriate
specialists listed below.
Document Number Industry Contact Phone (202)
EPA/310-R-95-001. Dry Cleaning Industry Joyce Chandler 564-7073
EPA/310-R-95-002. Electronics and Computer Industry* Steve Hoover 564-7007
EPA/310-R-95-003. Wood Furniture and Fixtures Industry Bob Marshall 564-7021
EPA/310-R-95-004. Inorganic Chemical Industry* Walter DeRieux 564-7067
EPA/310-R-95-005. Iron and Steel Industry Maria Malave 564-7027
EPA/310-R-95-006. Lumber and Wood Products Industry Seth Heminway 564-7017
EPA/310-R-95-007. Fabricated Metal Products Industry* Scott Throwe 564-7013
EPA/310-R-95-008. Metal Mining Industry Jane Engert 564-5021
EPA/310-R-95-009. Motor Vehicle Assembly Industry Anthony Raia 564-6045
EPA/310-R-95-010. Nonferrous Metals Industry Jane Engert 564-5021
EPA/310-R-95-011. Non-Fuel, Non-Metal Mining Industry Rob Lischinsky 564-2628
EPA/310-R-95-012. Organic Chemical Industry* Walter DeRieux 564-7067
EPA/310-R-95-013. Petroleum Refining Industry Tom Ripp 564-7003
EPA/310-R-95-014. Printing Industry Ginger Gotliffe 564-7072
EPA/310-R-95-015. Pulp and Paper Industry Seth Heminway 564-7017
EPA/310-R-95-016. Rubber and Plastic Industry Maria Malave 564-7027
EPA/310-R-95-017. Stone, Clay, Glass, and Concrete Industry Scott Throwe 564-7013
EPA/310-R-95-018. Transportation Equipment Cleaning Ind. Virginia Lathrop 564-7057
EPA/310-R-97-001. Air Transportation Industry Virginia Lathrop 564-7057
EPA/310-R-97-002. Ground Transportation Industry Virginia Lathrop 564-7057
EPA/310-R-97-003. Water Transportation Industry Virginia Lathrop 564-7057
EPA/310-R-97-004. Metal Casting Industry Jane Engert 564-5021
EPA/310-R-97-005. Pharmaceuticals Industry Emily Chow 564-7071
EPA/310-R-97-006. Plastic Resin and Man-made Fiber Ind. Sally Sasnett 564-7074
EPA/310-R-97-007. Fossil Fuel Electric Power Generation Ind. Rafael Sanchez 564-7028
EPA/310-R-97-008. Shipbuilding and Repair Industry Anthony Raia 564-6045
EPA/310-R-97-009. Textile Industry Belinda Breidenbach 564-7022
EPA/310-R-97-010. Sector Notebook Data Refresh-1997 Seth Heminway 564-7017
EPA/310-R-98-001. Aerospace Industry Anthony Raia 564-6045
EPA/310-R-98-002. Agricultural Chemical, Pesticide, and Shruti Sanghavi 564-4158
Fertilizer Industry
EPA/310-R-98-003. Agricultural Crop Production Industry Ginah Mortensen [phone]
EPA/310-R-98-004. Agricultural Livestock Production Ind. Ginah Mortensen [phone]
EPA/310-R-98-005. Oil and Gas Exploration and Production Dan Chadwick 564-7054
Industry
EPA/310-R-98-006. Local Government Operations John Dombrowski 564-7036
*Spanish translations available.
Sector Notebook Project November 1998
Aerospace Industry Sector Notebook Project
AEROSPACE INDUSTRY
TABLE OF CONTENTS
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
LIST OF ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
I. INTRODUCTION TO THE SECTOR NOTEBOOK PROJECT . . . . . . . . . . . . . . . . . . . . . 1
A. Summary of the Sector Notebook Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
II. INTRODUCTION TO THE AEROSPACE INDUSTRY . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Introduction, Background, and Scope of the Notebook . . . . . . . . . . . . . . . . . . . . . . 3
B. Characterization of the Aerospace Industry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Product Characterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Industry Size and Geographic Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. Economic Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
III. INDUSTRIAL PROCESS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A. Aircraft Engines and Parts Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1. Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2. Metal Shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3. Metal Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
B. Aircraft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
C. Repair/Rework Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
D. Space Vehicles and Guided Missiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
E. Raw Materials Inputs and Pollution Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F. Management of Chemicals in Wastestream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
IV. CHEMICAL RELEASE AND TRANSFER PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . 41
A. EPA Toxic Release Inventory for the Aerospace Industry . . . . . . . . . . . . . . . . . . . . 44
B. Summary of Selected Chemicals Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
C. Other Data Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
D. Comparison of Toxic Release Inventory Between Selected Industries . . . . . . . . . . . 56
V. POLLUTION PREVENTION OPPORTUNITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
A. Machining and Metalworking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
B. Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
C. Solvent Cleaning and Degreasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
D. Metal Plating and Surface Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
E. Painting and Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
VI. SUMMARY OF FEDERAL STATUTES AND REGULATIONS . . . . . . . . . . . . . . . . . . 75
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Aerospace Industry Sector Notebook Project
A. General Description of Major Statutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
B. Industry Specific Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
C. Pending and Proposed Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 91
VII. COMPLIANCE AND ENFORCEMENT HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
A. Aerospace Industry Compliance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
B. Comparison of Enforcement Activity Between Selected Industries . . . . . . . . . . . . . 98
C. Review of Major Legal Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1. Review of Major Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2. Supplementary Environmental Projects (SEPs) . . . . . . . . . . . . . . . . . . . . . . 103
VIII. COMPLIANCE ASSURANCE ACTIVITIES AND INITIATIVES . . . . . . . . . . . . . . 104
A. Sector-related Environmental Programs and Activities . . . . . . . . . . . . . . . . . . . . . 104
1. Federal Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
B. EPA Voluntary Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
C. Trade Association/Industry Sponsored Activity . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1. Industry Research Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2. Trade Associations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
IX. CONTACTS/ACKNOWLEDGMENTS/RESOURCE MATERIALS . . . . . . . . . . . . . . . 118
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Aerospace Industry Sector Notebook Project
LIST OF FIGURES
Figure 1: Structure of the Aerospace Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2: Number of Establishments and Value of Shipments for the Aerospace Industry . . . . . 8
Figure 3: Value of Shipments and Number of Establishments for the Aircraft Industry . . . . . . . 9
Figure 4: Value of Shipments and Number of Establishments for the Space Vehicles and
Guided Missiles Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 5: Geographic Distribution of Aerospace Manufacturing Facilities . . . . . . . . . . . . . . . . 11
Figure 6: The Aerospace Manufacturing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 7: Summary of TRI Releases and Transfers by Industry . . . . . . . . . . . . . . . . . . . . . . . . 57
LIST OF TABLES
Table 1: Products Included in the Aerospace Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 2: Facility Size Distribution for the Aerospace Industry . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 3: States with the Largest Number of Aerospace Manufacturing Facilities . . . . . . . . . . . 13
Table 4: Top U.S. Aerospace Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 5: Primary and Secondary Shaping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 6: Material Input and Pollutant Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 7: Source Reduction and Recycling Activity for Aerospace Manufacturers Facilities
(SICs 372 or 376) as Reported within TRI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 8: 1996 TRI Releases for Aerospace Chemicals Facilities . . . . . . . . . . . . . . . . . . . . . . . 46
Table 9: 1996 TRI Transfers for Aerospace Chemicals Facilities . . . . . . . . . . . . . . . . . . . . . . . 47
Table 10: Top 10 TRI Releasing Facilities Reporting Only 372 or 376 SIC Codes to TRI . . . . 48
Table 11: Top 10 TRI Releasing Facilities Reporting Aerospace SIC Codes to TRI . . . . . . . . 49
Table 12: Air Pollutant Releases by Industry Sector (tons/year) . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 13: 1995 Toxics Release Inventory Data for Selected Industries . . . . . . . . . . . . . . . . . . . 57
Table 14: Five-Year Enforcement and Compliance Summary for the Aerospace Industry . . . . 97
Table 15: Five-Year Enforcement and Compliance Summary for Selected Industries . . . . . . . . 99
Table 16: One-Year Enforcement and Compliance Summary for Selected Industries . . . . . . . 100
Table 17: Five-Year Inspection and Enforcement Summary by Statute for Selected
Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 18: One-Year Inspection and Enforcement Summary by Statute for Selected
Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Table 19: Aerospace Industry Participation in the 33/50 Program . . . . . . . . . . . . . . . . . . . . . 107
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Aerospace Industry Sector Notebook Project
LIST OF ACRONYMS
AIA- Aerospace Industries Association
AFS - AIRS Facility Subsystem (CAA database)
AIRS - Aerometric Information Retrieval System (CAA database)
BIFs - Boilers and Industrial Furnaces (RCRA)
BOD - Biochemical Oxygen Demand
CAA - Clean Air Act
CAAA - Clean Air Act Amendments of 1990
CARB- California Air Resources Board
CERCLA - Comprehensive Environmental Response, Compensation and Liability Act
CERCLIS - CERCLA Information System
CFCs - Chlorofluorocarbons
CO - Carbon Monoxide
COD - Chemical Oxygen Demand
CSI - Common Sense Initiative
CWA - Clean Water Act
D&B - Dun and Bradstreet Marketing Index
DOC- Department of Commerce
DOD- Department of Defense
DOE- Department of Energy
ELP - Environmental Leadership Program
EPA - United States Environmental Protection Agency
EPCRA - Emergency Planning and Community Right-to-Know Act
FIFRA - Federal Insecticide, Fungicide, and Rodenticide Act
FINDS - Facility Indexing System
GPS- Global Positioning System
HAPs - Hazardous Air Pollutants (CAA)
HSDB - Hazardous Substances Data Bank
HVLP- High Volume/Low Pressure
IDEA - Integrated Data for Enforcement Analysis
LDR - Land Disposal Restrictions (RCRA)
LEPCs - Local Emergency Planning Committees
MACT - Maximum Achievable Control Technology (CAA)
MCLGs - Maximum Contaminant Level Goals
MCLs - Maximum Contaminant Levels
MEK - Methyl Ethyl Ketone
MSDSs - Material Safety Data Sheets
NAAQS - National Ambient Air Quality Standards (CAA)
NAFTA - North American Free Trade Agreement
NAICS- North American Industrial Classification System
NCDB - National Compliance Database (for TSCA, FIFRA, EPCRA)
NCP - National Oil and Hazardous Substances Pollution Contingency Plan
NEC- Not Elsewhere Classified
NEIC - National Enforcement Investigation Center
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Aerospace Industry Sector Notebook Project
NESHAP - National Emission Standards for Hazardous Air Pollutants
NO - Nitrogen Dioxide
2
NOV - Notice of Violation
NO - Nitrogen Oxide
X
NPDES - National Pollution Discharge Elimination System (CWA)
NPL - National Priorities List
NRC - National Response Center
NRMRL- National Risk Management Research Laboratory
NSPS - New Source Performance Standards (CAA)
OAQPS- Office of Air Quality Planning and Standards
OAR - Office of Air and Radiation
OECA - Office of Enforcement and Compliance Assurance
OEM- Original Equipment Manufacturer
OMB- Office of Management and Budget
OPA - Oil Pollution Act
OPPTS - Office of Prevention, Pesticides, and Toxic Substances
OSHA - Occupational Safety and Health Administration
OSW - Office of Solid Waste
OSWER - Office of Solid Waste and Emergency Response
OW - Office of Water
P2 - Pollution Prevention
PCS - Permit Compliance System (CWA Database)
POTW - Publicly Owned Treatments Works
RCRA - Resource Conservation and Recovery Act
RCRIS - RCRA Information System
SARA - Superfund Amendments and Reauthorization Act
SDWA - Safe Drinking Water Act
SEPs - Supplementary Environmental Projects
SERCs - State Emergency Response Commissions
SIC - Standard Industrial Classification
SO - Sulfur Dioxide
2
SO - Sulfur Oxides
X
TOC - Total Organic Carbon
TRI - Toxic Release Inventory
TRIS - Toxic Release Inventory System
TCRIS - Toxic Chemical Release Inventory System
TSCA - Toxic Substances Control Act
TSS - Total Suspended Solids
UIC - Underground Injection Control (SDWA)
UST - Underground Storage Tanks (RCRA)
VOCs - Volatile Organic Compounds
Sector Notebook Project v November 1998
Aerospace Industry Sector Notebook Project
I. INTRODUCTION TO THE SECTOR NOTEBOOK PROJECT
I.A. Summary of the Sector Notebook Project
Environmental policies based upon comprehensive analysis of air, water and
land pollution (such as economic sector, and community-based approaches)
are becoming an important supplement to traditional single-media approaches
to environmental protection. Environmental regulatory agencies are beginning
to embrace comprehensive, multi-statute solutions to facility permitting,
compliance assurance, education/outreach, research, and regulatory
development issues. The central concepts driving the new policy direction are
that pollutant releases to each environmental medium (air, water and land)
affect each other, and that environmental strategies must actively identify and
address these interrelationships by designing policies for the "whole" facility.
One way to achieve a whole facility focus is to design environmental policies
for similar industrial facilities. By doing so, environmental concerns that are
common to the manufacturing of similar products can be addressed in a
comprehensive manner. Recognition of the need to develop the industrial
"
sector-based” approach within the EPA Office of Compliance led to the
creation of this document.
The Sector Notebook Project was initiated by the Office of Compliance within
the Office of Enforcement and Compliance Assurance (OECA) to provide its
staff and managers with summary information for eighteen specific industrial
sectors. As other EPA offices, states, the regulated community,
environmental groups, and the public became interested in this project, the
scope of the original project was expanded. The ability to design
comprehensive, common sense environmental protection measures for specific
industries is dependent on knowledge of several interrelated topics. For the
purposes of this project, the key elements chosen for inclusion are: general
industry information (economic and geographic); a description of industrial
processes; pollution outputs; pollution prevention opportunities; Federal
statutory and regulatory framework; compliance history; and a description of
partnerships that have been formed between regulatory agencies, the regulated
community and the public.
For any given industry, each topic listed above could alone be the subject of
a lengthy volume. However, in order to produce a manageable document, this
project focuses on providing summary information for each topic. This
format provides the reader with a synopsis of each issue, and references where
more in-depth information is available. Text within each profile was
researched from a variety of sources, and was usually condensed from more
detailed sources pertaining to specific topics. This approach allows for a wide
coverage of activities that can be further explored based upon the references
listed at the end of this profile. As a check on the information included, each
notebook went through an external document review process. The Office of
Sector Notebook Project 1 November 1998